Tehnicki podaci motora
1 Accelerator pedal position (APP) sensor - above pedal
2 Accelerator pedal position (APP) switch - in APP sensor
3 Barometric pressure (BARO) sensor - in ECM
4 Brake pedal position (BPP) switch 1/2 - above pedal
5 Clutch pedal position (CPP) switch - above pedal
6 Crankshaft position (CKP) sensor
7 Data link connector (DLC) - behind driver's side glove box
8 Engine control module (ECM)
9 Engine control (EC) relay - fascia relay plate 2
10 Engine coolant temperature (ECT) sensor
11 Exhaust gas recirculation (EGR) solenoid
12 Exhaust gas recirculation (EGR) throttle control valve
13 Fuel injection pump
14 Fuel injection timing solenoid
15 Fuel quantity adjuster
16 Fuel quantity adjuster position sensor
17 Fuel shut-off solenoid
18 Fuel temperature sensor
19 Glow plug relay - fascia relay plate 2
20 Glow plugs
21 Injectors
22 Injector needle lift sensor
23 Intake air temperature (IAT) sensor
24 Vehicle speed sensor (VSS) - transmission
Vehicle identification
No. of cylinders Type 4/OHC
Capacity cc 1896
Compression ratio :1 19,5
Injection system
Fuel/injection pump assembly Make Bosch
Fuel/injection pump assembly Type VP
Pump type Rotary
Injection sequence 1-3-4-2
Nozzle opening pressure - new/used bar 190-200/170
Leak rate (dribble) bar/secs 150/10
Tuning and emissions
Crankshaft position (n = ATDC) °BTDC 0
Adjusting method Engine/Pump Special Tool/ Special Tool
Idle speed rpm 825-950
13 Rated no load speed rpm
Oil temperature °C 80
Idle speed - for smoke test rpm 825-950
Maximum time at governed speed secs 0,5
Test mode A/B B
Probe type 1/2 1
Conditioning Accelerations/rpm10/2425±50
Smoke opacity - EU limit m-1 (%) 2,50 (66)
Smoke opacity - homologation value m-1 (%) 2,50 (66)
Starting and charging
Battery V/RC(Ah) 12 (70)
Maximum cranking amps A 189-231
Alternator output A/V/rpm 120/-/-
Glow plugs
Glow plug nominal rating V/A 11,5/12
Glow plug - part no. Beru 857 MJ
Glow plug - part no. Bosch 0 250 202 022
Glow plug - part no. Champion CH171
Service checks and adjustments
Valve clearance - INLET mm Hydraulic
Valve clearance - EXHAUST mm Hydraulic
Compression pressure bar 25-31
Oil pressure bar/rpm 2,0/2000
Radiator cap bar 1,2-1,5
Thermostat (primary/secondary) open °C 85
Lubricants and capacities
4 Engine oil grade - cold climate SAE 5W/30
4 Engine oil grade - moderate climate SAE 10W/40
4 Engine oil grade - hot climate SAE 20W/50
Engine oil classification API/ACEA CH/B2
4 Engine oil grade - alternative - moderate climate SAE 15W/40
Engine oil classification - alternative - moderate climate API/ACEA CH/B2
Engine with filter(s) litres 4,3
Manual gearbox oil grade SAE 75W/90 Synthetic
Manual gearbox 4/5 speed litres 1,9
Cooling system litres 6,6
Brake fluid Type DOT 4
Brake fluid litres 0,4 ABS=0,5
Power steering fluid Type CHF 11S
Power steering fluid litres 0,8
Tightening torques
Cylinder head instructions
Cylinder head
Renew boltsYes
Stage 1 Tighten 40 Nm
Stage 2 Tighten 60 Nm
Stage 3 Tighten 90°
Stage 4 Tighten 90°
Other tightening torques
Main bearings Renew bolts/nutsYes
Main bearings Stage 1 65 Nm
Main bearings Stage 2 90°
Big end bearings Renew bolts/nutsYes
Big end bearings Stage 1 30 Nm
Big end bearings Stage 2 90°
Oil pump to cylinder block 15 Nm
Sump bolts 15 Nm
Sump drain bolt 30 Nm
1 Flywheel/driveplate 60 Nm+90°
Clutch to flywheel 20 Nm
1 Crankshaft pulley/damper centre bolt 120 Nm+90°
Camshaft sprocket/gear 45 Nm
Camshaft carrier/cap 20 Nm
Camshaft/rocker cover 10 Nm
Inlet manifold to cylinder head 20 Nm
2 Exhaust manifold to cylinder head 25 Nm
2 Exhaust downpipe to manifold 40 Nm
Water pump 15 Nm
Injector/clamp 20 Nm
Injector pipe unions 25 Nm
14 Fuel/injection pump sprocket/gear
Fuel/injection pump flange 30 Nm
Fuel/injection pump mounting 25 Nm
Glow plugs 15 Nm
Engine oil pressure switch 20 Nm
Oil filter 25 Nm
7 Front hub
2 Rear hub 70 Nm+30°
2 Steering track rod end 20 Nm+90°
Brake disc to hub Front 4 Nm
Brake caliper to carrier Front 28 Nm
ABS sensor Front 8 Nm
ABS sensor Rear 8 Nm
Road wheels 120 Nm
Brake disc and drum dimensions
Minimum disc thickness - ventilated Front 19 mm
Maximum drum diameter Rear 201 mm
Minimum pad thickness Front 2 mm
Minimum shoe thickness Rear 1,5 mm
Air conditioning
Air conditioning refrigerant Type R134a
Air conditioning refrigerant quantity grams 550±25
Air conditioning oil Type G052 300 A2
Air conditioning oil quantity cmł 140±10
Air conditioning oil viscosity ISO 46
Cold climate = 5W/30 or 5W/40 semi-synthetic
Moderate climate = 10W/30 or 10W/40 semi-synthetic
Hot climate = 10W/40 semi-synthetic
Longlife service = 0W/30 synthetic to VW specification 506.01
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